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Unrestricted © Siemens Energy Inc. 2016 All rights reserved. http://siemens.com/energy/power-generation/gas-turbines

“Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency”DE-FE0023955

UTSR 2017 Conference

DPREF-60987040

01-Nov- 2017

Unrestricted © Siemens Energy Inc. 2017 All rights reserved. Jay Morrison / Siemens Energy Inc.CMC Advanced Transition

CMC Advanced Transition for > 65% CCProgram Overview

Content of Today’s Presentation

Supporting CMC Technology Development33

22

11 Program Overview & Rationale

Design Evolution & Status

Conclusions & Next Steps44

01-Nov- 2017


Towards a 65% CC system

SGT6-8000HSGT6-5000F

SGT6-2000E

SGT6-6000G

DOE targets are driving a step change in GT combustion technology

DOE FOA:R&D complete by 2020

with deployment by 2025

Silo combustor

ULN Combustor

Next Gen Combustor

* 60Hz Demonstrated Commercial operation

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Towards a 65% CC system

4

65% CC efficiency targets Firing Temperature > 1700ºCNOx emissions become limiting

Source: Ibrahim et. al (2012)

Brayton Cycle

• Plant output and efficiency improved by raising the top of the cycle

• i.e. Higher firing temperature and pressure.

Rankine Cycle• Plant output and efficiency

improved with better utilization of GT Exhaust energy.

• i.e. Higher bottoming steam temperature and pressure.

Brayton Cycle Rankine Cycle

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency NOx Reduction Approaches

Enablers:• Increase premixing quality• Decrease residence time• Diluents

Enablers:• Reduced Cooling &

Leakage Air (between flame and rotor inlet)

Combustion technology approach

CMC technology approach

CMC Technology approach to NOx reduction is additive to conventional approaches

Focus of this program

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Introduction

Objectives (Phase 2):Manufacture & test CMC inlet for Siemens Advanced Transition (TRL5)Design CMC exit for AT (TRL3)

Benefits:Reduction in Cooling Air NOx reduction or RIT increaseCO reduction (eliminate wall quenching)Reduced aero losses• Due to cooling air mixing• Due to cooling air ducting

Premise:Existing Siemens’ CMC materialNo through-wall cooling (backside only)Shape conducive to CMC manufactureDurability demonstrated in 25K hr testReadily tested in combustor rigs

Concept schematic

Experience base

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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle Efficiency Benefits: Cooling Air Reduction

NOx emissions reduction at High Firing Temperatures

CMC Inlet

CMC Inlet & Exit

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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle Efficiency Benefits: NOx Decrease vs. RIT Increase

Dec

reas

ing

NO

x

1) Constant Rotor Inlet Temperature 2) Constant NOx

Emissions Benefit Power & Efficiency Benefit

Flame Temperature

Rotor Inlet Temperature

Reduced cooling & leakage air between flame

and turbine rotor

Incr

easi

ng R

IT

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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle Efficiency CMC Technology Status

Combining two high pay-off technologies individually developed & tested

Siemens’ Advanced TransitionBlade Tip

Seals engine tested

Airfoils demonstrated in rig testing

+

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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle Efficiency CMC Component Testing Summary

Bench testingMechanical, thermal, fatigue, impact, etc.

Rig testingSimulated engine conditionsDurability under combined loadingsSubscale & Full Scale components

Engine testingCustomer site / durabilityBTF engine

Ring segments (4 types), airfoils, subelements

Combustors, Airfoils, Ring segments (4 types)

Combustor Ring Segment

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Program Overview



22




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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle Efficiency CMC AT Concept Down-selection Process

49

9 Milestone Sept 2015 Two Concepts

Structural CMC’s Heat Shields

5

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Advance Transition Concepts

Feature Concept 1 Concept 2 Concept 3CMC duty Thermal + Structural Thermal-only Thermal + Structural

Flow sleeve attachment Sliding Sliding Fixed (axially)

Inlet ring attachment Pinned Pinned Pinned

Aft Attachment (Exit Piece) Fixed Fixed Sliding

Cooling scheme Shell air (regenerative) Radiation + convection Shell air (regenerative)

Sealing difficulty Moderate Easy Difficult

Set-based-design approach increases chances of success

Metal shell Sliding jointFixed joint

CMC linerCMC CMC

Three uniquely different concepts were selected to offer complementary design challenges, learning experiences, and engine benefits. (performance / first cost / life-cycle-cost).

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Advance Transition Manufacturing Status (COIC)

Cones being manufactured by COIC

As-Fabricated ConditionConcept 2

Thinner (heatshield) version

All parts made via involute wrap

Concept 1

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Additive Manufacturing

Additive Manufacturing plays key role in AT components

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CMC Advanced Transition for > 65% CCProgram Overview



22




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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency CMC Mechanics – Current Status

Core Topics:• Deformation & Strength• Dynamics• CMC/TBC Modeling

Bi-Axial Failure Model

Involute Layup modeled explicitly in FEM

Predicted Stress & Failure

• Bi-axial failure model allows the interaction of different stress states to interact with one another, debiting or augmenting the design allowables.

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• Test Matrix Finalized - Specimens ordered (currently in machining)

• Goal is to fill out Woehler curve (Life defined by vibratory stress) for lifing components for HCF

Standardized Method Devloped in this program for damping measurement

Applied to initial cone dynamics analyses

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• Similar approach as in fluid dynamics• Output many outputs from FEM model, determine which are

significant• Construct life prediction based on a function of significant

non-dimensionalized parameters.• Ideas is “leave the black box” not “understand everything.”

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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencySupporting CMC Data & Remaining Challenges

Coupon Test Data Damage Accumulation & Life Prediction Tools

Remaining Design / Materials Challenges• Load-sharing mechanisms for hybrid metal-

CMC constructions

• Sealing methods for high temperature

• Metal-to-CMC Interfaces:• Wear resistance (anti-wear coatings)• Contact stresses / inserts / compliant layers

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• Casselberry Labs (CLAB)

• Flow & Leakages (test samples + full cone)

• Material Strength & attachment

• TBC

• HHFT

• wear

• Cincinnati Test Labs (CTL )

• Material (involute wrap)

• Florida Turbine Tech. (FTT)

• Ping Testing (coupons & full cones)

• Shaker Table (full cone, concept #1)

• Clean Energy Center (CEC)

• Cone (full, pressure, combustion tests, 4 concepts)

Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Test Activity Summary

Manufacturing peer review held as workshop in April 2017

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Seal Testing for CMC Cone: On-going Seal TestsFlow

Test plan: • Pressure ratios: 1.2, 1.4, 1.6, 1.8, 2.0• Seal gaps: 0mm, 0.13mm, 0.64mm,

1.016mm and 1.27mm• Pre-compression

Aluminum fixture for holding CMC

Slotted blocks can be interchanged to fit component applicationBlock is adjustable to test different gaps

SealCM

C

Seal types:• Rope seals (several types)• E-seals• Piston rings

Flow

Seal flow testing has identified several options to reduce leakage and improve cooling & leakage air useage further

01-Nov- 2017


Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Seal Testing for CMC Cone: Subelements for Test

Setup for CLAB flow testing

Results• CMC-CMC joint was as fabricated, and

showed the highest leakage, but still well within targeted values.

Next steps:• Testing various seal configurations • E-seal testing• Full assembly cone leakage tests

CMC-Metal leakage is less than predicted. Anticipated benefits exceeding targets.

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Full scale leakage testing

Full scale component assembly (attachments & seals) leakage testing conducted. Performance as expected based on coupon testing.

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Material Strength Testing

Comparison of current CMC to ca 2005 database shows good agreement(Lower cost 3000 denier fabric used in current design)

Testing of involute layup specimens in progress

No. of cycles

Max

imum

Str

ess

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Attachment testing for Concept 1

3X Static design load capability – Fatigue testing in progress

Design load (scaled to coupon)

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency CMC Material & TBC Testing

Method used for rapid screening & semi-quantitative ranking of CMC-TBC bonding concepts

CMC-TBC bond test : 1-day procedure established at CLAB

Steps:• Coating, • Adhesive Preparation, • Curation,• Testing

Sampletesting

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency CMC + TBC Testing

Method used for rapid screening & semi-quantitative ranking of CMC-TBC bonding concepts

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Ping Testing

Validation data being gathered for calibration of CMC modal analysis

Free – Free setup Fixed – Free setup Cone setup

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Shaker table test (FTT)

FTT shaker table used to validate modal analysis method. Apply validated method for CEC testing of cones.

Fixed - Free

Fixed – Free(axial) / Fixed (radial)

Comparison of predicted and holography testing is ongoing

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Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency Combustor Rig Testing

6 cone tests planned at Siemens’ Clean Energy Centre in Q1/Q2 FY18

2 Variants

3 Variants

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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle Efficiency Next Steps

PHASE 2 Technology Development & Testing

PHASE 1Concept Feasibility

PHASE 2/3Technology Demonstration

Conceptual Design

Manufacture & Combustor Rig Testing

Engine Testing

Next Step: Technology Demonstration

Next Steps:• Complete hardware manufacture• Assemble & Instrument• Combustor rig test• (Possible) engine test

01-Nov- 2017


Acknowledgements

• This work is performed under US Department of Energy Award Number DE-FE0023955.

• This program is based upon prior work supported by the US Department of Energy, under Award Number DE-FC26-05NT42644.

• The Siemens team wishes to thank Dr. Seth Lawson, NETL Project Manager for the opportunity to collaborate on the development of these novel technologies.

&

01-Nov- 2017


Answers for Energy.

Thank You. Questions?

Jay MorrisonPrincipal Investigator - Ceramic Matrix Composite Advanced Transition for 65% Combined Cycle Efficiency

Siemens Energy Inc.4400 Alafaya TrailOrlando, FL 32826Phone: +1 (407) 736-2000

E-mail:[email protected]

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